Method and apparatus for manufacturing photographic film and photographic film cassette

ABSTRACT

A photographic film cassette manufacturing apparatus, has a perforator for providing a long film with perforations and a cutter for cutting the long film into individual filmstrips to be contained in the film cassette driven synchronously with transport of the long film. A magnetic recording head for recording data on a magnetic recording layer of the long film is driven in synchronism with the perforator and the cutter. The long film is transported in a first direction before being cut into the individual filmstrips. In cooperation with the cutting, a trailing end of the individual filmstrip in the first direction is moved in a direction which is reverse to the first direction to secure the trailing end to the spool. A cassette shell consisting of a pair of shell halves is temporarily assembled by mating the shell halves together while containing a spool inside the shell halves, and thereafter opened to an extent that confining elements still confine the position of flanges of the spool. The trailing end of the filmstrip is inserted into the opened cassette shell and secured to the spool.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a method of, and an apparatusfor, manufacturing photographic film and photographic film cassettes.More particularly, the present invention relates to a method of, and anapparatus for, manufacturing a photographic filmstrip having apredetermined length and perforations, and data magnetically recordedthereon. The present invention also relates to a method of, and anapparatus for, cutting and winding the photographic filmstrip. Thepresent disclosure is based on the disclosures of Japanese Patent Appln.Nos. 4-206653, 4-272987 and 4-326982 filed August 3, October 12 andDecember 7, respectively, which disclosures are incorporated herein byreference.

[0003] 2. Description of the Related Art

[0004] A photographic film cassette is constituted of a cassette shell,and a roll of photographic film accommodated in the cassette shell inlight-tight fashion. 35 mm (135 type) film cassettes or cartridges arewell known.

[0005] Generally, a photographic filmstrip to be loaded in a cassetteshell is manufactured by the following process. First, a sheet of filmhaving a photosensitive emulsion layer applied on one surface thereon isslit to a predetermined width, and a consequent long strip ofphotographic film is wound about a rotary shaft, which is driven by amotor, into a roll. The long film is drawn from the roll and transportedat a constant speed along a manufactured line. In the manufacturingline, a perforator forms perforations in the film at regular intervals.The long film having the perforations formed therethrough is then cut topredetermined lengths to form individual filmstrips.

[0006] An automatic film cutting and winding apparatus whichsequentially performs the process of drawing the long film by apredetermined length from the roll, cutting the long film at thepredetermined length from the roll into individual filmstrips,transferring the individual filmstrip from the cutting position to asecuring position, securing the filmstrip to a spool, and winding thefilmstrip on the spool, is well known.

[0007] Such an automatic film cutting and winding apparatus isdisclosed, for example, in Japanese Patent Publication 63-4036, JPA2-222946 and JPA 3-182451. In the apparatus disclosed in Japanese PatentPublication 63-4036, there is a film feeding and measuring section, acutting section, an intermediate holder for storing a length of the longfilm that is approximately equal to the predetermined length of theindividual filmstrip, a feed roller section for feeding the filmstripout of the intermediate holder, and a film securing section,sequentially disposed in that order along a film transport path forfeeding the long film from the roll toward the spool. The transientstock in the intermediate holder contributes to shortening a stand-byperiod in each of the above sections.

[0008] In the apparatus disclosed in JPA 2-222946, a film feeding andmeasuring section, a cutting section, a feed roller section and a filmsecuring section are sequentially disposed on the film transport path inorder from the roll, to feed a filmstrip cut from the long film to aspool and secure the filmstrip to the spool. Thereafter, the feed rollersection releases the remaining portion of the filmstrip therefrom, andthe filmstrip is wound onto the spool.

[0009] The most popular 135 type photographic film cassette has acassette shell constructed of cylindrical barrel made of sheet metal anda pair of caps attached to opposite ends of the barrel. A spool with aphotographic film wound thereon is loaded in the cassette shell.According to a method as known from Japanese Patent Publication 2-691,the photographic film is wound on the spool, and then subsequentlywrapped with the barrel and the caps in a darkroom. Also a method forassembling such a conventional film cassette is known from JapanesePatent Publication 60-48748 wherein a temporary assembled cassette shellis partly disassembled in a film loading section disposed in a darkroom,to insert the spool with a film wound thereon into the cassette shell.Thereafter, the cassette shell is reassembled.

[0010] Furthermore, a photographic film cassette of a leader advancingtype is disclosed, for example, in U.S. Pat. Nos. 4,834,306 and4,846,418, and JPA 3-37645, wherein a cassette shell is constructed ofresin molded products and a leading end of a filmstrip wound on a spoolcan be advanced to the outside of the cassette shell by rotating thespool in an unwinding direction. Because the leading end of thefilmstrip is located inside the cassette shell not only after exposurebut also before loading of this type of film cassette, light-shieldingof the contained filmstrip is improved, and handling of the filmcassette, during the loading and the removal thereof is easier ascompared with conventional 135 type film cassettes.

[0011] Recently, a photographic film has been disclosed in U.S. Pat.Nos. 4,860,037 and 4,864,332, on which film data specific to thephotographic film is magnetically recorded. The film data represents,for example, an ID code, a lot number and a film speed of the film, aswell as the number of available frames in the film. The data is read byan appropriate device incorporated in a camera when the photographicfilm is loaded in the camera. Based on the data, a suitable photographymode of the camera is automatically selected, for example, to facilitatetaking a high quality photograph.

[0012] When finishing the photographic film in a photolab, it isnecessary to always correlate the respective photographic films with thecustomers throughout the photo-finishing process. Therefore, data usablefor such a correlation is also recorded on the photographic film.Japanese Patent Publication 3-2905 discloses a photographic filmstriphaving discrimination data recorded in the vicinity of a perforation inassociated with an exposure position in which an image frame is to beexposed. The discrimination data is binary data representing numericalvalues specific to each individual filmstrip, such as slit data, asupplementary number, etc . . . And the discrimination data ismagnetically recorded and/or photographically recorded as a latent barcode image or the like.

[0013] In order to record such magnetic data on the photographicfilmstrip, a magnetic recording layer is provided in a predeterminedposition on the long film, on a side thereof which is opposite from thephotosensitive emulsion layer, before the long film is wound in a roll.

[0014] However, when recording data on the magnetic recording layer, ithas been very difficult to precisely position the data in correspondencewith each image frame exposure position on the film, because the longfilm is transported at a very high speed during the film manufacturing,for example, at a speed of several tens of the ordinary film advancingspeed in cameras, to increase production efficiency.

[0015] Besides, it is impossible to exactly read the magnetic data fromthe photographic film unless each recording position has a definitepositional relation to the image frame exposure position which isdesignated by a perforation or the like. Data reading is necessaryduring manufacturing, for checking if the data has been properlyrecorded on the magnetic recording layer.

[0016] When securing a first end of the filmstrip, it is necessary toguide the first end into an engaging portion of the spool with accuracy,and protect the filmstrip from being scratched or blushed during theguiding. Such scratching or blushing may result in lowering the qualityof the filmstrip to a certain degree.

[0017] In spite of this fact, conventional automatic film cutting andwinding apparatus guide the filmstrip through a relatively long distancetoward the spool. That is, the filmstrip is transported in the samedirection as in the measuring and cutting process toward the spool.Therefore, the first end to be secured to the spool is the forward endin the transporting direction, and the securing position, where thefirst end is secured to the spool, is spaced apart from the cuttingposition of the long film, by at least a distance corresponding to thelength of the individual filmstrip.

[0018] As a result, the first end cannot always be accuratelypositioned, because of shrinkage or curling of the filmstrip, variancein the transport amount of the filmstrip, and also fluctuation ofcurvature of the filmstrip during the slitting operation. Therefore, ithas been very difficult to quickly and precisely guide and secure thefirst end of the filmstrip to the spool without scratching and blushingthereof. This hinders rapid manufacturing of the film cassette. Thisproblem is especially serious because photographic films are beingmanufacture thinner and thinner in the interest of minimizing materialsand lightening cameras.

[0019] In the above-described leader advance type photographic filmcassette, it is necessary, for permitting the film advancing operation,to prevent loosening of the roll of the photographic film wound on thespool when the spool is rotated in the unwinding direction. For thispurpose, a photographic film cassette wherein flanges, which confine theopposite sides of the film roll on the spool, are formed from relativelysoft material and/or formed separately from the spool core is known.When the spool is mounted in the cassette shell, the flanges are pressedagainst the opposite sides of the film roll by confining members formedintegrally inside the cassette shell. Thereby, the film roll is tightlyheld by the flanges at opposite sides thereof and thus is prevented fromloosening.

[0020] When manufacturing such a film cassette, if the photographic filmis first wound on the spool having the soft or separate flanges thereon,and thereafter the spool is mounted in the cassette shell, the flangescan be deformed or damaged by the confining members during the mountingof the spool in the cassette shell or during closing of the cassetteshell. This is because the position of the flanges is unstable when notpressed by the confining members. For the same reason, the flanges arefrequently not properly positioned inside the confining member inconventional manufacturing processes.

[0021] The present invention is directed to solving the above-describedproblems and thus an object of the present invention is to provide amethod of, and an apparatus for, manufacturing a photographic filmhaving a magnetic recording layer, wherein data can be magneticallyrecorded exactly in proper position relative to each image frameexposure position and/or relative to either end of each individualfilmstrip.

[0022] Another object of the present invention is to provide a methodof, and an apparatus for, manufacturing a photographic film cassette,wherein the positioning of the photographic filmstrip can be performedwith accuracy when securing the filmstrip to the spool.

[0023] A further object of the present invention is to provide a methodof, and an apparatus for, manufacturing a photographic film cassette,which makes it possible to reliably wind the filmstrip into the cassetteshell in the manufacturing process even when the spool has soft flangesor when the cassette shell and/or the flanges are separate parts fromthe spool core.

SUMMARY OF THE INVENTION

[0024] To achieve the above and other objects, according to the presentinvention, a perforator is driven synchronously with transport of a longfilm, and a magnetic recording head is driven in synchronism with theperforator. Thereby, magnetic data is positioned precisely inassociation with each image frame exposure position or area.

[0025] When recording data magnetically on at least one end of anindividual filmstrip, a cutter for cutting the long film into theindividual filmstrips is driven synchronously with transport of the longfilm, and a magnetic recording head is driven in synchronism with thecutter.

[0026] The present invention transports the long film in a firstdirection during the measuring process for measuring a predeterminedlength of an individual filmstrip, holds a trailing end of theindividual filmstrip in relation to the first direction immediatelybefore or after cutting the filmstrip from the long film, and moves thefilmstrip by a predetermined distance in a second direction, which isreverse to the first direction, while holding the trailing end to securethe trailing end to a spool. Accordingly, the filmstrip can be guidedthrough a relatively short path to the spool with accuracy whileavoiding scratching or blushing of the filmstrip.

[0027] When manufacturing a photographic film cassette that includes aspool having soft or elastic flanges formed separately from a spool coreand fitted to the spool core, the cassette shell is temporarilyassembled by mating shell halves together while containing the spoolfitted with the flanges inside the shell halves. The cassette shell isthen opened to an extent that confining elements still contact theflanges and confine the position of the flanges. One end of thefilmstrip is then inserted into the opened cassette shell to be securedto the spool, and thereafter, the shell halves are mated together againto close the cassette shell. Then, the spool is rotated to wind thefilmstrip into the cassette shell. Accordingly, the confining elementscan not interfere with the flanges, so that the flanges are not damagedby the confining elements and are positioned properly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Other objects and advantages of the present invention will becomeapparent based on the following detailed description of the preferredembodiments when read in connection with the accompanying drawings,wherein like reference numerals designate like or corresponding partsthroughout the several views, and wherein:

[0029]FIG. 1 is an exploded perspective view of a photographic filmcassette to be manufactured according to the preferred embodiment of thepresent invention;

[0030]FIG. 2 is an explanatory view of an example of a photographicfilmstrip contained in the photographic film cassette shown in FIG. 1;

[0031]FIG. 3 is an explanatory view of a portion of a long strip ofphotographic film which is cut into the individual filmstrips having apredetermined length each;

[0032]FIG. 4 is an explanatory view of the overall construction of acassette manufacturing apparatus according to a preferred embodiment ofthe present invention;

[0033]FIG. 5 is an explanatory view of a film manufacturing section of acassette manufacturing apparatus according to another embodiment of thepresent invention;

[0034]FIG. 6 is an explanatory view of a film manufacturing section of acassette manufacturing apparatus according to yet another embodiment ofthe present invention;

[0035]FIG. 7 is an explanatory view of a film cutting and windingsection of a cassette manufacturing apparatus according to yet anotherembodiment of the present invention;

[0036]FIG. 8 is an explanatory view of a cut-out portion of a long stripof photographic film which is cut into individual filmstrips to be woundon a spool and loaded in a cassette shell;

[0037]FIG. 9 is a perspective view of an example of the spool;

[0038]FIG. 10 is an explanatory view of a cutter and an inserter of thefilm cutting and winding section is shown in FIG. 7;

[0039]FIG. 11 is a sectional view of the inserter, showing a protrudingposition of a table of the inserter in relation to a spool;

[0040]FIG. 12 is a section view of the inserter in a securing positionwherein the table is in a retracted position and the trailing end of thefilmstrip can be secured to the spool;

[0041]FIG. 13 is an explanatory view of a film winding unit of the filmcutting and winding section of FIG. 7;

[0042]FIG. 14 is a side view of the film winding unit, partly insection;

[0043]FIG. 15 are timing charts illustrating the operation of the filmcutting and winding section of FIG. 7;

[0044]FIG. 16 is an explanatory view of another embodiment of the cutterand the inserter of the film cutting and winding section of FIG. 7;

[0045]FIG. 17 is an explanatory view of another embodiment of the cutterand the inserter of the film cutting and winding section of FIG. 7;

[0046]FIG. 18 is an exploded perspective view of a photographic filmcassette having a different construction from that shown in FIG. 1;

[0047]FIG. 19 is an explanatory view of a film winding section of acassette manufacturing apparatus according to another embodiment of thepresent invention, which is suitable for manufacturing the photographicfilm cassette as shown in FIG. 18;

[0048]FIG. 20 is a top plane view of a nest of the film winding sectionof FIG. 19, holding a cassette shell therein;

[0049]FIG. 21 is an explanatory view of film inserting and securingoperation in the film winding section of FIG. 19;

[0050]FIG. 22 is a vertical sectional view of the nest shown in FIG. 21;and

[0051]FIG. 23 is a partial sectional view showing a relationship betweena ridge of a lower shell half and a flange of a spool in an openedposition of the cassette shell as shown in FIG. 21.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0052] An example of a photographic film cassette manufactured accordingto a preferred embodiment of the present invention is shown in FIG. 1.The cassette 2 is composed of a cassette shell 3, a spool 4 rotatablymounted in the cassette shell 3 and a photographic filmstrip 5 having apredetermined length. A pair of shell halves 3 a and 3 b constitute thecassette shell 3. The spool 4 includes a cylindrical spool core or hub 4a and a pair of flanges 4 b disposed on opposite ends of the spool core4 a. In an initial state, the entire length of the photographicfilmstrip 5, hereinafter referred to as simply a filmstrip, is tightlywound about the spool core 4 a and located inside the cassette shell 3with the lateral sides thereof confined by the flanges 4 b. Theoutermost convolution of the roll of the filmstrip 5 is confined byridges 6 formed integrally on the inside surface of the shell halves 3 aand 3 b. Therefore, the roll of the filmstrip 5 will not come unwound inthe initial state.

[0053] The opposite ends of the spool core 4 a are exposed to theoutside of the cassette shell 3, but not protrude beyond the lateral endfaces of the cassette shell 3. The upper and lower shell halves 3 a and3 b have respective port portions 8 and 9 which define a film passageway11 of the filmstrip 5 when the shell halves 3 a and 3 b are joinedtogether. Light-trapping members 10 are cemented on the opposing innerwalls of the port portions 8 and 9. A separating claw 12 is formed at aninner portion of the port portion 9 of the lower shell half 3 b.

[0054] When the spool 4 is rotated in a clockwise direction in FIG. 1,by coupling a rotating device to one end of the spool core 4 a, the rollof filmstrip 5 is rotated along with the spool 4 in the cassette shell3. At that time, a leading end 5 a of the filmstrip 5 is pealed off thenext inward convolution of the roll, by the separator claw 12, andguided to the outside of the cassette shell 3 through the film passagemouth 11. This function is referred to as a film advance function.

[0055] As shown in FIG. 2, the photographic filmstrip 5 has perforations13 a formed therethrough in association with a leading margin and atrailing margin of each image frame exposure area 5 c. The perforations13 a are used for positioning the image frame exposure area 5 c. Also,perforations 13 b are formed in the leading end 5 a on opposite lateralsides thereof for facilitating catching of the leading end 5 a by a feedmechanism. A magnetic recording track 14 a is formed on each lateralside of the image frame exposure area 5 c between adjacent perforations13 a which indicate the leading and trailing margins of the same imageframe exposure area 5 c. These magnetic recording tracks 14 a have filmdata, such as an identification code, recorded thereon. The magneticrecording tracks 14 b are also provided in the vicinity of the leadingend 5 a and/or a trailing end 5 e of the filmstrip 5 along the lateralsides thereof.

[0056] The perforations 13 a and 13 b and the magnetic recording tracks14 a are formed in a long strip of photographic film (hereinafterreferred to as a long film) 15. A magnetic recording layer is previouslyprovided on one surface of the long film 15 opposite to thephotosensitive emulsion surface thereof, in the form of a pair ofcontinuous zones extending along the opposite lateral sides of the longfilm 15. After forming the perforations 13 a and 13 b and recording thefilm data on the magnetic recording tracks 14 a and 14 b, the long film15 is cut into the individual filmstrips 5 in a manner as shown in FIG.3, wherein a hatched area 15 a shows a cut-out portion.

[0057]FIG. 4 illustrates a cassette manufacturing apparatus forperforming a preferred embodiment of a method of the present invention.The long film 15, on which the photosensitive emulsion layer andmagnetic recording layer are formed, is wound in a roll and fitted on arotary shaft in a film manufacturing section 16 of the cassettemanufacturing apparatus. The rotary shaft is driven by a motor (notshown) to feed the long film 15 longitudinally to a transporting systemincluding a pair of feed rollers 18 a and 18 b. The feed rollers 18 aand 18 b transport the long film 15 at a predetermined speed, e.g.,about 1 to 5 m/second.

[0058] First, the perforations 13 a and 13 b are formed by a perforator17 which is driven synchronously with the film transport. Next, amagnetic recording head 19 records data on the magnetic recording track14 a in synchronism with the perforator 17. The length of the long film15 extending between the perforator 17 and the recording head 19 ismaintained constant. Just downstream of the recording head 19, amagnetic reading head 20 is disposed to read and check the data havingbeen recorded by the recording head 19. The data recorded by therecording head 19 may include the frame number, the film speed, the nameof film manufacturer, and the like.

[0059] The long film 15 having the perforations 13 a and 13 b formedtherein and as the film data recorded thereon, is transported to acutter 21. The cutter 21 is also driven synchronously with the filmtransport, to cut the long film 15 in the way shown in FIG. 3, toprovide the individual filmstrip 5. The filmstrip 5 is transported byanother pair of feed rollers 22 a and 22 b toward a cassette assemblingsection 30.

[0060] A second magnetic recording head 23 is disposed downstream of thecutter 21, to record film data in the vicinity of the leading end 5 aand/or the trailing end 5 e of the filmstrip 5 along the magneticrecording track 14 b. The second magnetic recording head 23 is drivensynchronously with the cutter 21. Also the length of the filmstrip 5extending between the cutter 21 and the second recording head 23 isdisposed just downstream from the second recording head 23 to read andcheck data having been recorded by the second recording head 23. Thedata recorded by the second recording head 23 may include the totalavailable number of frames, the film speed, the name of filmmanufacturer, a lot number, data relating to manufacture, and the like.The film data may be appropriately located in the magnetic recordingtracks 14 a and 14 b.

[0061] The cassette assembling section 30 is constituted of a spoolreceiving station 30 a where the spool 4, formed in another process, isreceived in the cassette assembling section 30, a film winding station30 b where the filmstrip 5 is wound on the spool 4, and a shellassembling station 30 c where the spool 4 having the filmstrip 5 woundthereon is mounted in the cassette shell 3.

[0062] The shell assembling station 30 c is provided with an upperholder 31 and a lower holder 32 which are movable up and down to movetoward or away from each other. The upper holder 31 holds the uppershell half 3 a by suction force and transports the same downward tocover the upper half portion of the film roll 5 wound on the spool 4,whereas the lower holder 32 supports the lower shell half 3 b andtransports the same upward to cover the lower half portion of the filmroll 5. After the shell halves 3 a and 3 b are thus mated together, theupper and lower holders 31 and 32 are retracted to allow transfer of thecassette shell 3 containing the spool 4 and the filmstrip 5 therein ontoa carrier 33 by a transport device (not illustrated). Then, anultrasonic horn 34 secures the shell halves 3 a and 3 b to each other byultrasonic welding.

[0063] The operation of the above-described cassette manufacturingapparatus is described below.

[0064] The photosensitive emulsion layer is provided on one surface ofthe long film 15 and the magnetic recording layer is provided on theopposite surface outside the image frame exposure areas 5 c. Thereafter,the long film 15 is wound in a roll and loaded in the cassettemanufacturing apparatus.

[0065] The feed rollers 18 a and 18 b are driven by a step motor (notshown) to intermittently stop transporting the filmstrip 15 atpredetermined intervals. The perforator 17 forms the perforations 13 aand 13 b in the long film 15 when the filmstrip 5 is intermittentlystopped. Thereafter, the recording head 19 writes the film data on themagnetic recording track 14 a while the long film 15 is transported bythe feed rollers 18 a and 18 b. Because the length of the long film 15between the perforator 17 and the recording head 19 is maintainedconstant, the location of the magnetic recording tracks 14 a relative tothe perforations 13 a is also maintained unchanged, so that the filmdata is recorded in a predetermined location in relation to each imageframe exposure area 5 c. The recording head 19 is brought into contactwith the long film 15 during the recording only, and is retractedtherefrom at other times to avoid damage the surface of the film 15.

[0066] The reading head 20 reads the data recorded by the recording head19 while the filmstrip 15 is transported. Because the reading head 20 isdisposed just downstream of the recording head 19, the data can bereproduced at the substantially same time as the recording thereof.Therefore, specific synchronization of the reproduced data with therecording position during the reproduction is unnecessary. Thiscontributes to simplifying the process of data checking.

[0067] The long film 15 is further transported to the cutter 21 to becut into the individual filmstrip 5 to be contained in the film cassette2. The second pair of feed rollers 22 a and 22 b are also driven by astep motor to intermittently stop transporting the long film 15 atpredetermined intervals. The cutter 21 cuts the long film 15 when thetransporting is intermittently stopped. Thereafter, while the individualfilmstrip 5 is transported by the feed rollers 22 a and 22 b, the secondrecording head 23 records the film data on the magnetic recording track14 b of the leading end 5 a and/or that of the trailing end 5 e. Becausethe length of the filmstrip 5 between the cutter 21 and the secondrecording head 23 is maintained constant, the location of the magneticrecording track 14 b is maintained unchanged.

[0068] The filmstrip 5, cut to the predetermined length and having thefilm data recorded thereon, is transported by the feed rollers 22 a and22 b to the film winding station 30 b of the cassette assembling section30, wherein the trailing end 5 e is secured to the spool 4 previouslyreceived in the spool receiving station 30 a. Thereafter, the entirelength of the filmstrip 5 is wound on the spool 4 by a winding device(not illustrated).

[0069] The spool 4, with the filmstrip 5 wound thereon, is transportedto the shell assembling station 30 c, wherein the upper and lower shellhalves 3 a and 3 b are mated together to rotatably mount the spool 4between the shell halves 3 a and 3 b. Thereafter, the ultrasonic horn 34applies ultrasonic vibration to the cassette shell 3 to join the shellhalves 3 a and 3 b together into one body.

[0070] The photographic film cassette 2 thus manufactured is subjectedto inspection for inspecting the construction and function of the filmcassette 2. Only those film cassettes 2 which have passed the inspectionare packed and shipped for sale.

[0071] Instead of checking the data recorded by the recording head 23directly after the recording, it is possible to check the data recordedon the magnetic recording track 14 b of the leading end 5 asimultaneously with inspecting the film-advance-function of the finishedphotographic film cassette 2. In this embodiment, a magnetic readinghead 25 for reading the data recorded on the magnetic recording track 14b of the leading end 5 a is disposed outside of the film passage mouth11 of the photographic film cassette 2 which is positioned in afilm-advance-function inspecting section, wherein the spool 4 is rotatedby a rotating device 26 to advance the leading end 5 a of the filmstrip5 to the outside through the film passage mouth 11. Thereafter, thefilmstrip 5 is rewound into the cassette shell 3.

[0072] In the above-described embodiments, the transport of the longfilm 15 stops when the perforations 13 a and 13 b are formed by theperforator 17, and is resumed while the film data is recorded by therecording head 19. In order to reliably maintain the length of the longfilm 15 between the perforator 17 and recording head 19 at a constantvalue, it is preferable to provide a buffer portion 35 for reserving acertain amount of a loop of the long film 15 between the perforator 17and the recording head 19, as is shown in FIG. 5. In this embodiment, aloop sensor 36 is provided at a bottom portion of the loop to measureand control the amount of the loop contained in the buffer portion 35.

[0073] For example, the length of the long film 15 extending between theperforator 17 and the recording head 19 is M times longer than theinterval of the image frame exposure areas 5 c (M is an integer), suchthat one of the perforation 13 a is located right in front of therecording head 19 at the moment when the long film 15 stops and theperforator 17 forms the perforation 13 a. The recording head 19 startsrecording a short time after the resume of transport of the filmstrip15. As a result, the film data is recorded on the magnetic recordingtrack 14 a in association with each image frame exposure area 5 c asshown in FIG. 2.

[0074] Also, a second buffer portion 37 can be provided between thecutter 21 and the second recording head 23, to store a loop of apredetermined amount of the individual filmstrip 5. For example, thelength of the filmstrip 5 between the cutter 21 and the second recordinghead 23 is set to equal the predetermined total length of the filmstrip5. Thereby, the trailing end 5 e of the filmstrip 5 is located right infront of the second recording head 23 when the cutter 21 starts cuttingof the leading end 5 a of the same filmstrip 5 and the trailing end 5 eof the following filmstrip 5 as well. Therefore, the magnetic recordingtrack 13 b is reliably recorded in the trailing end 5 e, as illustratedin FIG. 3. Other portions of this embodiment can be similar to theembodiment shown in FIG. 4, and the filmstrip 5 thus manufactured may beassembled into the film cassette 2 in the cassette assembling section 30as shown in FIG. 4. Therefore, a detailed description of these portionsis omitted.

[0075]FIG. 6 illustrates another embodiment of the present invention. Inthis embodiment, the long film 15 is transported to an oscillatingperforator 38. The oscillating perforator 38 is driven synchronouslywith the film transport, and the magnetic recording head 19 is driven insynchronism with the oscillating perforator 38. The oscillatingperforator 38 makes it unnecessary to stop transporting the long film 15during forming the perforations 13 a and 13 b. Therefore, theoscillating perforator 38 can form the perforations 13 a and 13 b whilethe recording head 19 records the film data. However, in order to recordthe film data at regular intervals in predetermined positions, it isnecessary to maintain the distance between the start perforatingposition of the oscillating perforator 38 and the recording head 19 inrelation to the long film 15.

[0076] That is, the oscillating perforator 38 forms the perforations 13a and 13 b while moving a constant distance back and forth in the filmtransporting direction, but the perforator 38 always starts perforatingat the same position in the moving range thereof. Therefore, thedistance between the start perforating positions of the oscillatingperforator 38 and the recording head 19 is set, for example, M timeslonger than the interval of the image frame exposure areas 5 c (M is aninteger), such that one of the perforation 13 a is located right infront of the recording head 19 at the moment when the oscillatingperforator 38 starts perforating. The recording head 19 starts recordinga short time later. As a result, the film data is recorded on themagnetic recording track 14 a in association with each image frameexposure area 5 c as shown in FIG. 2.

[0077] Also an oscillating cutter 39 is provided for cutting the longfilm 15 into the individual filmstrip 5 without the need for stoppingthe transport of the long film 15. The distance between the oscillatingcutter 39 and the second recording head 23 should be maintainedconstant, to make the length of the filmstrip 5 constant. For example,the distance between the oscillating cutter 39 and the second recordinghead 23 is set to equal the predetermined length of the filmstrip 5.Thereby, the trailing end 5 e of the filmstrip 5 is located right infront of the second recording head 23 when the oscillating cutter 39starts cutting the leading end 5 a of the same filmstrip 5 and thetrailing end 5 e of the following filmstrip 5. Therefore, the film datais recorded on the magnetic recording track 14 b of the trailing end 5e, as shown in FIG. 3. Other portions of this embodiment can be similarto the embodiment shown in FIG. 4, and the filmstrip 5 thus manufacturedmay be assembled into the film cassette 2 in the cassette assemblingsection 30 as shown in FIG. 4. Therefore, further detailed descriptionis omitted.

[0078] Although the magnetic recording layer is provided along bothlateral sides of the long film 15 on the surface opposite to thephotosensitive emulsion surface in the above described embodiment, it ispossible to provide the magnetic recording layer along one lateral sideor on the whole surface of the long film 15 opposite to thephotosensitive emulsion surface. It is also possible to dispose aphoto-sensor or the like in an upstream portion of each of the recordingheads 19 and 23 to more precisely determine the recording position.

[0079] Although the filmstrip 5 is wound on the spool 4 and thereafterthe spool 4 with the filmstrip 5 is loaded in the cassette shell 3 inthe above described embodiment, it is of course possible to mount thespool 4 in the cassette shell 3 and thereafter secure the filmstrip 5 tothe spool 4 and wind it into the cassette shell 3.

[0080]FIG. 7 illustrates a film cutting and winding section of acassette manufacturing apparatus according to another embodiment of thepresent invention. A long film 15 is drawn from a roll and transportedlongitudinally along a film transport path. A puncher 42, for punching apair of holes 5 f in the long film 15, as shown in FIG. 8, at regularintervals corresponding to the length of an individual filmstrip 5 to bewound about a spool 4, a measuring feeder 43, a cutter 44, and a shooter45 are disposed along the transport path in order in a transportingdirection A.

[0081] The pair of holes 5 f are arranged side by side in the lateraldirection of the long film 15. Thereafter, the cutter 44 cuts out aportion 15 a from the long film 15 to form a trailing end 5 e of thefilmstrip 5 and a leading end 5 a of the next filmstrip 5 in a manner asshown by chain-dotted lines in FIG. 8, in relation to the transportingdirection A.

[0082] The measuring feeder 43 includes a pair of feed rollers 43 a and43 b and stepwise transports the long film 15 by a given amount in thedirection A, to insert a forward portion of the long film 15, that is,the portion corresponding to an unfinished one of the filmstrip 5, intothe shooter 45. Thereby, a rearward portion of the long film 15 that isto be cut out as the portion 15 a is positioned in the cutter 44. Upondetermining the given amount of transport of the long film 15, themeasuring feeder 43 stops the long film 15 for a short period of timeand the cutter 44 cuts the long film 15.

[0083] The shooter 45 is constituted of upper and lower guide plates 48and 49 disposed above and below the film transport path. The upper guideplate 48 is stationary and provided with rollers 50 a, 51 a and 52 a.The lower guide plate 49 is provided with rollers 50 b, 51 b and 52 bdisposed in opposition to the rollers 50 a, 51 a and 52 a, respectively.The lower guide plate 49 is movable between a closed position fornipping the long film 15 by the rollers 50 a, 50 b, 51 a, 51 b, 52 a and52 b, and an open position for displacing the filmstrip 5 cut from thelong film 15 downward from the film transport path. The rollers 50 a, 50b, 51 a, 51 b and 52 a, 52 b are driven to rotate in the same way at thesame speed as the feed rollers 43 a and 43 b. If the filmstrip 5 nippedby the shooter 45 has any defects, the filmstrip 5 is ejected from theshooter 45 in a direction shown by an arrow B in FIG. 7 by means of therollers 50 a, 50 b, 51 a, 51 b, 52 a and 52 b, and a pair of rollers 53a and 53 b disposed downstream of the shooter 45.

[0084] An inserter 46 is disposed in the vicinity of the cutter 44. Theinserter 46 moves the filmstrip 5 cut from the long film 15 in adirection C, which is opposite to the direction A, and inserts thetrailing end 5 e of the filmstrip 5 into a slit 4 c formed through aspool core 4 a of the spool 4 between flanges 4 b, as shown in FIG. 9,to secure the trailing end 5 e to the spool 4 through engagement betweenthe holes 5 f and claws 4 d formed in the slit 4 c. As shown in detailin FIG. 11, a rib 4 e is also formed in the slit 4 c to press thetrailing end 5 e at the portion between the holes 5 f to prevent theclaws 4 d from slipping out of the holes 5 f. After the trailing end 5 eis secured to the spool 4, the spool 4 is rotated to wind the filmstrip5 thereon by a drive mechanism of a winding unit 47, which is coupled toone end of the spool core 4 a, as will be described in detail later.

[0085] It is to be noted that the long film 15 is subjected to aperforating process and other necessary processes, prior to the cuttingand winding process shown in FIG. 7.

[0086]FIG. 10 illustrates the cutter 44. A cam 59 makes one revolutionto reciprocate a base plate 60 once in a vertical direction, that is,the direction perpendicular to the film transport path, to make onecutting stroke. The base plate 60 has cutting edges 61 and 62 spaced apredetermined distance apart from each other, and an ejection mechanism63 disposed between these cutting edges 61 and 62 to hold and discardthe cut portion 15 a by vacuum suction force. A stationary cutting edge64 is disposed in the opposite side of the film transport path from thecutting edges 61 and 62, in opposition to the space defined betweenthese cutting edges 61 and 62.

[0087] The base plate 60 also has a transfer 65 mounted thereto. Thetransfer 65 is vertically movable relative to the base plate 60 betweena position near the cutter 44 and a position near the inserter 46 placedin a stand-by position (see chain-dotted line). The transfer 65 has avacuum suction mechanism incorporated therein for holding the top sideof the long film 15 or the filmstrip 5. The transfer 65 also has acouple of pins 65 a protruding downward to engage in the holes 5 f andfix the position of the long film 15 during the cutting.

[0088] The inserter 46 is movable between the stand-by position shown inFIG. 10 and a securing position shown in FIG. 12. The moving direction Cfrom the stand-by position to the securing position is reverse to thedirection A. The inserter 46 is constituted of a base portion 67, atable 68, and a spring 69. The table 68 is slidable on the base portion67 parallel to the direction A between a position protruding from thebase portion in the direction C as shown in FIG. 11, and a retractedposition shown in FIG. 12. The spring 69 urges the table 68 toward theprotruding position. A hole 68 a is formed in the table 68 for receivingthe tip of the pin 65 a when the transfer 65 moves down to the inserter46. The base portion 67 and the table 68 contains vacuum suctionmechanisms 70, 71 a and 71 b for holding the bottom side of thefilmstrip 5. The power of the vacuum suction mechanism 71 a and 71 b ofthe table 68 is adjustable independently of the vacuum suction mechanism70 of the base portion 67.

[0089] As the inserter 46 is moving into the securing position, thetable 68 strikes against a stopper 73 of the winding unit 47, as shownin FIG. 11, and is thus pushed by the stopper 73 back to the retractedposition as the inserter 46 moves further into the securing position, asshown in FIG. 12. While the table 68 is being pushed back, the power ofthe vacuum suction mechanism 71 a and 71 b is lowered, so that thetrailing end 5 e, having been held by the table 68, slips off the table68 into the slit 4 c of the spool 4 placed in the winding unit 47. Thespool 4 is previously prepared and seriatim placed in the winding unit47 by a spool feeder 74.

[0090]FIGS. 13 and 14 illustrate an example of the winding unit 47. Thewinding unit 47 includes a holder 75 constructed of a pair of disks 76and 77 which are spaced vertically from each other and rotated togetherby a holder motor, e.g., a step motor 78. A plurality of, for examplesix, chuck mechanisms 79 are mounted to the disks 76 and 77 and disposedat regular intervals around the rotational axis of the disks 76 and 77.A slip ring 78 a is mounted on the rotary shaft of the step motor 78 todetect the rotational position of the holder 75.

[0091] Each chuck mechanism 79 has a pair of rotatable axles 80 and 81which protrude inward from the disks 76 and 77 and are axially movabletoward each other in a direction parallel to the rotational axis of thedisks 76 and 77 to engage in the opposite ends of the spool core 4 a.The spool 4 is thus rotatably chucked by the chuck mechanism 79. Apulley 82 is coupled to each axle 81 of the chuck mechanism 79.

[0092] A servo motor 83 is coupled to a pulley 84 which is rotatablymounted on the rotary shaft of the step motor 78. A pulley 85 is fixedlycoupled to the pulley 84. The holder 75 has a sleeve 78 fixedly mountedthereto and extending in coaxial with the rotational axis of the holder75, and six clutch brakes 86 are mounted on the periphery of the sleeve78 on the opposite side from the chuck mechanisms 79. A pulley 87 isfixedly coupled to an output shaft of each clutch brake 86, and a pulley88 is fixedly coupled to an input shaft of each clutch brake 86. The sixpulleys 88 are coupled to the pulley 85 through a timing belt 89 whichis turned about the pulleys 85 and 88 in a manner as shown by solid linein FIG. 13, by way of five press roller 90. The press rollers 90 aresecured to the sleeve 78.

[0093] On the other hand, the six pulleys 87 on the input shafts of theclutch brakes 86 are each coupled to the pulleys 82 in one-to-onerelation through a timing belt 91. In this way, the respective axles 81of the chuck mechanisms 79 are driven by the single servo motor 83 whilebeing individually rotated and stopped under the control of theassociated clutch brakes 86.

[0094] The holder 75 is rotated stepwise and pauses six times at regularintervals during one revolution. At the six stop positions of the chuckmechanisms 79, chucking of the spool 4 and orientation of the spool 4are sequentially performed. Therefore, the stop positions are referredto as work stations ST-1 to ST-6. At the work station ST-1, the spool 4,fed by the spool feeder 74, is chucked by one of the chuck mechanisms79. At the work station ST-2, the slit 4 c of the chucked spool 4 isoriented appropriately. At the work station ST-3, the filmstrip 5 issecured to the spool 4 by the inserter 46 in the above-described manner.Winding of the secured filmstrip 5 is performed at the work stationsST-4 and ST-5, and the spool 4 with the filmstrip 5 wound thereon isoutputted from the winding unit 47 at the work station ST-6. Thereafter,the spool 4 with the filmstrip 5 is inserted inside a pair of shellhalves constituting a cassette shell, and the shell halves are securedto each other, for example, by ultrasonic welding, thereby completing aphotographic film cassette.

[0095] The operation of the above-mentioned embodiment will now bedescribed with reference to the timing charts of FIG. 15.

[0096] The measuring feeder 43 stops transporting the long film 15 attime t1. Simultaneously, the cutter 14 cuts the long film 15 and,immediately before or after the cutting, the transfer 65 holds thetrailing end 5 e of the filmstrip 5 just cut from the long film 15.Thereafter, the lower guide plate 49 of the shooter 45 is moved into theopen position, and the transfer 65 transfers the filmstrip 5 to theinserter 46 placed in the stand-by position. This transferring operationis completed at time t2. At the same time t2, the holder 75 stopsrotating to position the spool 4 at the work station ST-3. Then, theinserter 46 holds the trailing end 5 e of the filmstrip 5 by the vacuumsuction force, whereas the transfer 65 releases the filmstrip 5 from thevacuum suction force thereof.

[0097] The inserter 46 moves the filmstrip 5 in the direction C, whichis reverse to the transporting direction A of the measuring feeder 43.When the inserter 46 reaches the securing position, the trailing end 5 eof the film is secured to the spool 4 placed in the work station ST-3.This securing operation is completed at time t3. At that time t3, theholder 75 is still stationary.

[0098] The holder 75 starts rotating again from time t4, and stops againat time t5. At that time t5, the spool 4, having the filmstrip 5 securedthereto, arrives at the work station ST-4. Simultaneously with the startof rotation of the holder 75 at the time t4, one of the clutch brakes86, that corresponds to the chuck mechanism 79 is positioned in the workstation ST-3 from the time t2 to t4, is activated. As a result, theservo motor 83 is connected to the axle 81 of this chuck mechanism 79 tostart winding of the filmstrip 5. The winding is conducted with onebreak or pause while the corresponding spool 4 is carried from the workstation ST-3 to the work station ST-5.

[0099] It is, of course, possible to start winding from the time t5 whenthe corresponding spool 4 arrives at the work station ST-4, and continuewinding until the corresponding spool arrives at the work station ST-6.

[0100]FIG. 16 shows another embodiment wherein the transfer 65 isomitted. Instead, an inserter 46 holds the trailing end 5 e of thefilmstrip 5 immediately before or after the cutting thereof. Thereafterwhen a shooter 45 moves in the open position, the inserter 46 displacesthe filmstrip 5 downward from the film transport path and then moves thefilmstrip 5 in the direction C until the filmstrip 5 is secured to thespool 4.

[0101] It is also possible to provide a cutting edge 95 on a table 68 ofan inserter 46 as shown in FIG. 17. In this embodiment, a stationarycutting die 64 is spaced apart from the cutting edge 95 incorrespondence with the cutout portion 15 a of the long film 15 as shownin FIG. 8, when the inserter 46 is in the stand-by position. A movablecutting die 96 is mounted on a base plate 60 and opposed to the spacingbetween the cutting die 64 and the cutting edge 95, to cut out theportion 15 a from the long film 15 by means of these cutting members 64,95 and 96.

[0102] Furthermore, in the embodiment shown in FIG. 17, in order topunch the holes 5 f simultaneously with the cutting of the long film 15,a pair of punching pins 97 are mounted on the base plate 60, andcorresponding holes having cutting edges 98 are formed in the table 68of the inserter 46.

[0103] Although the embodiments shown in FIGS. 7 to 17 have beendescribed with respect to a cassette manufacturing method wherein afilmstrip is wound on a spool before the spool is loaded in a cassetteshell, these embodiments are also applicable to such a cassettemanufacturing method wherein a spool is previously mounted in a cassetteshell, and thereafter a filmstrip is secured to the spool and wound intothe cassette shell.

[0104]FIG. 18 shows a photographic film cassette 100 having thesubstantially same construction as the photographic film cassette 2shown in FIG. 1, except a spool 101 has elastic flanges 103 madeseparately of resin material and fitted to the opposite ends of thespool core 102. The axial position of the flanges 103 on the spool core102 is confined by a pair of ridges 109 formed on the inner periphery ofa cassette shell 3 when the spool 101 is mounted in the cassette shell3. The ridges 109 press the flanges 103 at circumferential portionsthereof against lateral sides of a roll of filmstrip 5 wound on thespool core 102.

[0105] Each flange 103 has a rim 103 a curved to protrude inwardly inthe axial direction of the cassette 100 when fitted on the spool core102, to contact an outermost convolution of the film roll 5 at a lateralportion thereof and radially confine the outermost convolution. Thereby,loosening of the film roll 5 is prevented, and the film roll 5 isrotated together with the spool 101 when the spool 101 is rotated in anunwinding direction, that is, a clockwise direction in FIG. 18. As aresult, when the spool 101 is rotated, a leading end of the filmstrip 5is pealed off the next inward convolution by a separating claw 12 andthus advanced to the outside of the cassette shell 3 through a filmpassage mouth 11 which is formed between port portions 8 and 9 of upperand lower shell halves 3 a and 3 b constituting the cassette shell 3.Light-trapping members 10 are cemented to the inner wall of the portportions 8 and 9.

[0106] The spool core 102 has annular shoulders 102 a formed on oppositeend portions thereof to stop the flanges 103 from moving too farinwardly on the spool core 102. A slit 105 for receiving a trailing endof the filmstrip 5 is formed in the spool core 102, and a pair of claws106 and a pressing rib 107 are formed in the slit 102 to secure thetrailing end to the spool 101 through engagement between the claws 106and holes formed in the trailing end, in the same way as theabove-described embodiments.

[0107] Because the flanges 103 are elastic and separate parts, theposition of the flanges 103 on the spool core 102 is unstable unless theflanges are properly pressed by the ridges 109. Therefore, whenmanufacturing such a photographic film cassette as shown in FIG. 18, itis desirable to properly mount a spool with flanges in a cassette shelland thereafter wind a filmstrip into the cassette shell be securing thefilmstrip to the spool and then rotating the spool in a windingdirection. FIGS. 19 to 22 illustrate a cassette manufacturing apparatusaccording to an embodiment of the present invention for manufacturingthe film cassette 100 shown in FIG. 18.

[0108] Referring to FIG. 19 illustrating a film winding section of thecassette manufacturing apparatus, a rotational disk or table 120 has aplurality of, for example, six nests 122 each holding a cassette shell 3containing the spool 101 therein. The nests 122 are disposed at regularintervals around the rotational axis of the table 120, and sequentiallystopped at six work stations ST-1 to ST-6 disposed around the table 120at intervals corresponding to the nests 122.

[0109] A feeding conveyer 124 and a robot arm 125 are disposed in thework station ST-1. The feeding conveyer 124 successively feeds thecassette shells 3 containing the spool 101 to the work station ST-1, andthe robot arm 125 seriatim transfers the cassette shell 3 from theconveyer 124 to the nest 122 stopping at the work station ST-1. A pairof insert rollers 126 and a film guide 127 are movably disposed in thework station ST-3, as shown in detail in FIG. 21, wherein the cassetteshell 3 is opened by the nest 122, and the film guide 127 is insertedinto the opened cassette shell 3 so as to insert the trailing end 5 e ofthe filmstrip 5 into the slit 105 of the spool 101 contained in thecassette shell 3.

[0110] Thereafter, the spool 101 is rotated to wind the filmstrip 5entirely into the cassette shell 3. An output conveyer 128 and a robotarm 129 are disposed in the work station ST-6 wherein the robot arm 129grasps and transfers the cassette shell 3 containing the filmstrip 5therein onto the output conveyer 128. Then, the output conveyer 128sends the cassette shell 3 to the following process wherein the shellhalves 3 a and 3 b are secured to each other by welding.

[0111] Each nest 122 is comprised of a pair of holders 131 and 132 whichare shaped to conform to the outer curves of the upper and lower shellhalves 3 a and 3 b, respectively, as shown in FIGS. 20 and 22. The firstholder 131, for holding the upper shell half 3 a, is fixedly mounted onthe top of the table 120, and a clamp 133 is attached to the firstholder 131 through a shaft 133 a to be movable up and down relative tothe first holder 131. The shaft 133 a extends vertically through thefirst holder 131 to project under the table 120. A spring 135 is mountedbetween a lower end 133 b of the shaft 133 a and the bottom surface ofthe table 120, so as to urge the clamp 133 to move downward to the table120. Thereby, the upper shell half 3 a is clamped axially between theclamp 133 and a base surface 131 a of the first holder 131.

[0112] The second holder 132 is mounted to the table 120 through ahollow shaft 132 a to be pivotally and axially movable about the hollowshaft 132 a relative to the table 120. The hollow shaft 132 a is coupledto a not-shown control mechanism for controlling the pivotal and axialmovement of the second holder 132 through a lever 137 secured to thehollow shaft 132 a. Top and bottom clamps 138 and 139 for axiallyclamping the lower shell half 3 b are attached to the second holder 132through shafts 138 a, 138 b and 139 a to be movable up and down relativeto each other as well as to the second holder 132.

[0113] The first shaft 138 a of the top clamp 138 and the shaft 139 a ofthe bottom clamp 139 have rack gears 141 and 142 formed thereon,respectively. The rack gears 141 and 142 are coupled to each otherthrough a pinion 143, such that the clamps 138 and 139 are moved incooperation with each other in the opposite vertical directions to eachother. The second shaft 138 b of the top clamp 138 extends coaxiallythrough the hollow shaft 132 a of the second holder 132, and the lowerend 138 c of the second shaft 138 b projects under the table 120 beyondthe lower end of the hollow shaft 132 a. A spring 146 is mounted betweenthe lower end 138 b of the second shaft 138 a and the lower end of thehollow shaft 132 a so as to urge the top clamp 138 to move downward tothe table 120.

[0114] Furthermore, a fork shaft 148 is rotatably mounted to the table120 in a center position between the first and second holders 131 and132. The fork shaft 148 is also movable in an axial direction so as toengage into one end of the spool core 102 of the spool 101 mountedbetween the shell halves 3 a and 3 b. A gear 149 is fixedly mounted onthe lower end of the fork shaft 148. The fork shaft 148 is rotated by anot-shown drive mechanism through the gear 149.

[0115] As shown in FIG. 21, at the work station ST-3, the second holder132 pivots to rotate at an angle θ about the shaft 132 a to separate thelower shell half 3 b from the upper shell half 3 a to widen the filmpassage mouth 11. At that time, the flanges 103 are in contact with theridges 109 of the lower shell half 3 b by an amount L (see also FIG.23). If the amount L is too small, the flanges 103 can be damaged by theridges 109 or can be wrongly located relative to the ridge 109 when thelower shell half 3 b is reset to the initial position to be mated withthe upper shell half 3 a. The suitable amount L varies depending uponthe conditions of the ridges 109 and the flanges 103, such as the curveof rounded edges, stiffness, smoothness of the surface, and so forth.

[0116] According to the present embodiment, the amount L isexperimentally determined to be not less than 0.3 mm under the followingconditions: the external diameter a of the flanges 103 is 21.2 mm, theinternal diameter b of the cassette shell 3 is 22 mm, the radialdistance c from the rotational axis of the spool 101 to the inner end ofthe ridges 109 is 8 mm, the radial distance d from the pivotal center ofthe shaft 132 a to the axial center of the spool 101 is 14 mm, and theradius of curvature R of the rim 103 a of the flanges 103 (see FIG. 23)is 0.2 mm.

[0117] An experiment was performed by opening and closing the cassetteshell while varying the amount L from 0.1 mm to 0.6 mm by an incrementof 0.1 mm. The cassette shell 3 was opened and closed 20 times for eachincrement. The results of the experiment is shown in Table 1. TABLE 1 L(mm 0.1 0.2 0.3 0.4 0.5 0.6 TROUBLE C B A A A A

[0118] In Table 1, “A” means no problems occurred, “B” means problemsoccurred less than four times per the 20 times open-and closeoperations, and “C” means problems occurred 4 times or more. Therefore,it is clear that the amount L should be 0.3 mm or more for the cassetteas defined above in order to achieve desirable operation.

[0119] The operation of the embodiment shown in FIGS. 19 to 23 will nowbe described.

[0120] First, the light-trapping members 10 are cemented to the innerwalls of the port portions 8 and 9 of the upper and lower shell halves 3a and 3 b, for example, by means of heat-melting adhesive. Thereafter,the shell halves 3 a and 3 b are sent to a temporary assembling process(not-shown) wherein the shell halves 3 a and 3 b are mated togetherafter insertion of the spool 101 therebetween. The above process can beperformed in a lighted environment. Therefore, the elastic flanges 103can be unfailingly and easily positioned inside the ridges 109 in thecassette shell 3.

[0121] Next, the cassette shell 3, containing the spool 101 therein, isconveyed by the feed conveyer 124 to the work station ST-1 of the table120 which is disposed in a dark room. At the work station ST-1, thesecond holder 132 of the nest 122 is in an open position displacedpivotally away from the first holder 131. The clamps 138 and 139 are ina release position removed away from each other, and the clamp 133 ofthe first holder 131 is pushed upward, for example, by an oil hydrauliccylinder to provide a sufficient space enough to receive the cassetteshell 3. Therefore, the robot arm 125 sets the cassette shell 3 betweenthe holders 131 and 132 from the top side of the nest 122. Thereafter,the second holder 132 is moved in a close position shown in FIG. 20, andclamps 133, 138 and 139 are moved to clamp the cassette shell 3.

[0122] The table 120 rotates to move the clamped cassette shell 3 fromthe work station ST-1 to the work station ST-2. At the work stationST-2, the fork 48 engages into the spool core 102 and rotates the spool101 to direct an inlet of the slit 105, that is, the left hand side ofthe slit 105 in FIG. 21, to the outside of the table 120. While thetable 120 is rotating to move the cassette shell 3 from the work stationST-2 to the work station ST-3, the second holder 132 pivots at the angleθ to separate the shell halves 3 a and 3 b from each other to such anextent that the insertion of the film guide 127 into the cassette shell3 is permitted while the ridges 109 of the lower shell half 3 b arestill in contact with the flanges 103 by the amount L. Needless to say,the ridges 109 formed in the upper shell half 3 a stay in contact withthe flanges 103.

[0123] At the work station ST-3, the insertion rollers 126 and the filmguide 127 are moved together to a film loading position shown in FIG.21, wherein a forward end of the film guide 127 is inserted between theport portions 8 and 9, that is, the widened film passage mouth 11 into aposition close to and opposing to the inlet of the slit 105. Thereafter,the insertion rollers 26 are rotated, so that the filmstrip 5, which ispreviously provided with perforations and cut into a predeterminedlength, is transported toward the slit 105 through the film guide 127.When the trailing end 5 e of the filmstrip 5 is thus inserted into theslit 105, the claws 106 and the pressing rib 107 secures the filmstrip 5to the spool 101. Then, the rollers 126 and the film guide 127 are movedback to a retracted position to avoid interference with the rotation ofthe table 120.

[0124] While the table 120 is rotating to move the cassette shell 3 fromthe work station ST-3 to the work station ST-4, the second holder 132pivots back to the closed position to mate the shell halves 3 a and 3 btogether again. By virtue of the continued contact of the ridges 109with the flanges 103, the flanges 103 are smoothly and properlypositioned inside the ridges 109.

[0125] When the cassette shell 3 arrives at the work station ST-4, thefork 148 is driven to rotate the spool 101 to wind the filmstrip 5 aboutthe spool 101. Thereby, the filmstrip 5 is drawn into the cassette shell3 through the film passage mouth 11 until the filmstrip 5 has beenentirely located inside the cassette shell 3. For example, the drive ofthe fork 148 may be stopped upon a sensor detecting a predeterminedtension level of the filmstrip 5.

[0126] The table 120 further rotates to move the cassette shell 3containing the filmstrip 5 from the work station ST-4 to the workstation ST-6. In this embodiment, the work station ST-5 is merely a stopposition wherein no process is executed. At the work station ST-6, therobot arm 129 transfers the cassette shell 3 from the nest 122 to theoutput conveyer 128 to convey the cassette shell 3 to the next weldingprocess. The emptied nest 122 is moved to the work station ST-1 andsupplied with another cassette shell 3 having no film therein. Thus, theprocess above is repeated.

[0127] Although the above described embodiments relate to methods andapparatuses for manufacturing photographic film cassettes of leaderadvancing type, it is also possible to apply the invention tomanufacturing of other types of photographic film cassettes. Also thespool may have a single claw in the slit, or may have another filmsecuring mechanism.

[0128] Control and timing of the invention can be accomplished withknown devices. For example, a microprocessor based controller can beappropriately programmed and coupled to known sensors and drive devicessuch as motors and solenoids. Of course, hard-wired control systems canalso utilized.

[0129] While the present invention has been described in detail abovewith reference to a preferred embodiments shown in the drawings, it willbe apparent to those skilled in the art that various changes andmodifications of the present invention are possible without departingfrom the scope of the invention as defined by the appended claims.

What is claimed:
 1. A method of manufacturing a photographic filmcassette having a cassette shell, a spool rotatably mounted in saidcassette shell, and a photographic filmstrip wound around said spool,said photographic filmstrip having a magnetic recording layer formedthereon, said method comprising the steps of: recording data on saidmagnetic recording layer with a magnetic recording head; and thereafterloading said photographic filmstrip in said cassette shell.
 2. A methodof manufacturing a photographic film cassette as recited in claim 1,wherein said loading step comprises the steps of: transporting saidphotographic filmstrip in a longitudinal direction thereof toward saidspool along a film transport path to secure one end of said photographicfilmstrip to said spool; and winding said photographic filmstrip aroundsaid spool.
 3. A method of manufacturing a photographic film cassette asrecited in claim 2, wherein said cassette shell consists of a pair ofshell halves, and said loading step comprises the steps of insertingsaid spool with said photographic filmstrip wound thereon in betweensaid shell halves and thereafter joining said shell halves together bywelding.
 4. A method of manufacturing a photographic film cassette asrecited in claim 2, wherein said spool is mounted in said cassette shellbefore said winding step and said winding step comprises rotating saidspool in a winding direction.
 5. A method of manufacturing aphotographic film cassette as recited in claim 2, further comprising thestep of reading said data with a magnetic reading head before saidloading step, to check said data.
 6. A method of manufacturing aphotographic film cassette as recited in claim 5, wherein said magneticreading head is disposed adjacent to said magnetic recording headdownstream of said film transport path, and said reading step isexecuted immediately after said recording step while feeding saidphotographic filmstrip along said film transport path.
 7. A method ofmanufacturing a photographic film cassette as recited in claim 6,further comprising the step of: perforating said photographic filmstripwith a perforator at regular intervals along at least one lateral edgeof said photographic film in synchronism with said transporting step,said magnetic recording head being driven in synchronism with saidperforator.
 8. A method of manufacturing a photographic film cassette asrecited in claim 7, further comprising the step of maintaining thelength of said photographic filmstrip, between said perforator and saidmagnetic recording head.
 9. A method of manufacturing a photographicfilm cassette as recited in claim 8, wherein said perforations and saiddata are arranged in association with each image frame exposure area ofsaid photographic filmstrip.
 10. A method of manufacturing aphotographic film cassette as recited in claim 9, wherein saidtransporting step includes a feeding period and a pausing period, andsaid perforating step is executed in said pausing period, whereas saidrecording step is executed in said feeding period.
 11. A method ofmanufacturing a photographic film cassette as recited in claim 10,wherein said photographic filmstrip is transported continuously, andsaid perforator is an oscillating perforator.
 12. A method ofmanufacturing a photographic film cassette as recited in claim 2,wherein said photographic filmstrip has a predetermined length and saiddata is recorded at least one of the leading and trailing ends of saidphotographic filmstrip, further comprising the step of: cutting a longstrip of photographic film with a cutter into said predetermined length,said magnetic recording head being driven in synchronism with saidcutter.
 13. A method of manufacturing a photographic film cassette asrecite din claim 12, further comprising the step of maintaining thelength of said photographic filmstrip constant between said cutter andsaid recording head.
 14. A method of manufacturing a photographic filmcassette as recited in claim 12, wherein a magnetic reading head isdisposed adjacent to said magnetic recording head downstream thereof insaid film transport path, said method further comprising a reading stepof reading data with said reading head immediately after said recordingstep while feeding said photographic filmstrip along said film transportpath.
 15. A method of manufacturing a photographic film cassette asrecited in claim 12, wherein said transporting step includes a feedingperiod and a pausing period, and said cutting step is executed in saidpausing period, whereas said recording step is executed in said feedingperiod.
 16. A method of manufacturing a photographic film cassette asrecited in claim 12, wherein said photographic filmstrip is transportedcontinuously, and said cutter is an oscillating cutter.
 17. A method ofmanufacturing a photographic film cassette as recited in claim 2,wherein a leading end of said photographic filmstrip can be advanced outof said cassette shell, in advancing step, by rotating said spool in anunwinding direction, and said data is recorded on said leading end, saidmethod further comprising the steps of: reading said data after saidadvancing step of said leading end; and thereafter winding said leadingend back into said cassette shell by rotating said spool in a windingdirection.
 18. A method of manufacturing a photographic film cassettehaving a cassette shell, a spool rotatably mounted in said cassetteshell, and a photographic filmstrip coiled about said spool, saidphotographic filmstrip being entirely located in said cassette shell,and a leading end of said photographic filmstrip having a magneticrecording layer formed thereon and being advanced out of said cassetteshell through a film passage mouth formed in said cassette shell byrotating said spool in an unwinding direction, said method comprisingthe steps of: recording data with a magnetic recording head on saidleading end; loading said photographic filmstrip in said cassette shellafter said recording step; reading said data upon advancing said leadingend after said loading step; and winding said leading end back into saidcassette shell by rotating said spool in a winding direction.
 19. Amethod of manufacturing a photographic filmstrip having perforationsformed at regular intervals and data magnetically recorded thereon, saidmethod comprising the steps of: transporting said photographic filmstripin a longitudinal direction thereof; forming said perforations with aperforator in synchronism with said transporting step; and recordingsaid data with a magnetic recording head in synchronism with saidperforator.
 20. A method of manufacturing a photographic filmstrip asrecited in claim 19, further comprising the step of maintaining thelength of said photographic filmstrip, between said perforator and saidmagnetic recording head.
 21. A method of manufacturing a photographicfilmstrip as recited in claim 20, further comprising a step of readingsaid data with a magnetic recording head to check said data, whereinsaid magnetic reading is disposed adjacent to said magnetic recordinghead downstream of a film transport path, and said reading step isexecuted immediately after said recording step while feeding saidphotographic filmstrip along said film transport path.
 22. A method ofmanufacturing a photographic filmstrip having a predetermined length,perforations formed at regular intervals along at least one lateral edgeof said photographic filmstrip and data magnetically recorded on atleast one of leading and trailing ends of said photographic filmstrip,said method comprising the steps of: transporting a long strip ofphotographic film in a longitudinal direction thereof; cutting said longstrip of photographic film with a cutter into said predetermined lengthin synchronism with said transporting step; and recording said data witha magnetic recording head in synchronism with said cutter.
 23. A methodof manufacturing a photographic filmstrip as recited in claim 22,further comprising the steps of maintaining the length of saidphotographic filmstrip, between said cutter and said magnetic recordinghead counter.
 24. A method of manufacturing a photographic filmstrip asrecited in claim 23, further comprising a step of reading said data witha magnetic reading head to check said data, wherein said magneticreading head is disposed adjacent to said magnetic recording headdownstream in a film transport path, and said reading step is executeimmediately after said recording step while feeding said photographicfilmstrip along said film transport path.
 25. A method of manufacturinga photographic film cassette having a cassette shell, a spool rotatablymounted in said cassette shell, and a photographic filmstrip wound aboutsaid spool, a trailing end of said photographic filmstrip being securedto said spool, said method comprising the steps of: transporting a longstrip of photographic film longitudinally in a first direction along afilm transport path; cutting said long strip of photographic film intoan individual said photographic filmstrip while stopping saidtransporting for a moment when said long strip of photographic film hasbeen transported by a predetermined length in said first direction;holding said trailing end of said photographic filmstrip immediatelybefore or after said cutting step; moving said photographic filmstrip bya given distance in a second direction, which is reverse to said firstdirection, said trailing end to said spool; and rotating said spool towind said photographic filmstrip around said spool.
 26. A method ofmanufacturing a photographic film cassette as recited in claim 25,wherein said cassette shell consists of a pair of shell halves, and saidmethod further comprises the steps of inserting said spool with saidphotographic filmstrip wound thereon between said shell halves andthereafter joining said shell halves together.
 27. A method ofmanufacturing a photographic film cassette as recited in claim 25,further comprising the steps of: preparing and sending spools seriatimto a securing station where said securing step is executed; removingsaid spool from said securing station during said rotating step;ejecting said spool after said photographic filmstrip is completelywound on said spool; and controlling said preparing, removing andejecting steps to be executed in parallel.
 28. An apparatus formanufacturing a photographic film cassette having a cassette shell, aspool rotatably mounted in said cassette shell, and a photographicfilmstrip wound about said spool, a trailing end of said photographicfilmstrip being secured to said spool, said apparatus comprising: meansfor transporting a long strip of photographic film longitudinally in afirst direction along a film transport path; means for stopping saidtransporting means when said long strip of photographic film has beentransported by a predetermined length in said first direction; means forcutting said long strip of photographic film into an individual of saidphotographic filmstrip in cooperation with said stopping means; meansfor holding said trailing end of said photographic filmstrip incooperation with said cutting means and securing said trailing end to aspool by moving said filmstrip by a given distance in a second directionreverse to said first direction; means for winding said photographicfilmstrip on said spool by rotating said spool.
 29. An apparatus asrecited in claim 28, wherein said cassette shell consists of a pair ofshell halves, and said apparatus further comprises means for joiningsaid shell halves together after inserting said spool, with saidphotographic filmstrip wound thereon, between said shell halves.
 30. Anapparatus as recited in claim 28, wherein said holding means holds saidtrailing end immediately before or after said cutting means cuts saidlong strip of photographic film.
 31. An apparatus as recited in claim30, wherein said holding means holds said trailing end by vacuumsuction.
 32. An apparatus as recited in claim 31, wherein said trailingend is inserted in a slit formed in a spool core of said spool to beengaged with claws extending into said slit.
 33. An apparatus as recitedin claim 30, wherein said holding means comprises: a first means forholding said trailing end of said photographic filmstrip andtransferring said photographic filmstrip from said film transport pathto a second path; and a second means for holding and moving saidphotographic filmstrip in said second path by said given distance insaid second direction to secure said trailing end to said spool placeddownstream of said second path in said second direction.
 34. Anapparatus as recited in claim 33, wherein said first means is disposedabove said film transport path and shifts said filmstrip vertically fromsaid film transport path toward said second means which is disposedbelow said film transport path.
 35. An apparatus as recited in claim 34,wherein said second means comprises a base portion, a table slidable onsaid base portion, a spring urging said table to protrude from said baseportion in said second direction, and a vacuum suction deviceincorporated in said table, said base portion being moved in said seconddirection relative to said table while lowering power of said vacuumsuction device, so as to move said photographic filmstrip in said seconddirection.
 36. An apparatus as recited in claim 28, wherein said windingmeans comprises: a turntable; a plurality of chuck mechanisms mounted tosaid turntable and disposed around a rotational axis of said turntable,each of said chuck mechanisms holding an individual of said spool atopposite ends of said spool in parallel with said rotational axis; and adrive mechanism for rotating said turntable and said chuck mechanismssuch that said spool is seriatim moved in a position where said trailingend is secured to said spool and thereafter said spool is rotated towind said photographic filmstrip thereon.
 37. A method of manufacturinga photographic film cassette having a cassette shell consisting of apair of shell halves, a spool rotatably mounted in said cassette shell,a roll of photographic film tightly wound on said spool, a pair offlanges mounted on opposite ends of said spool to hold lateral sides ofsaid roll and prevent loosening of said roll, confining elements formedon the inner periphery of said cassette shell so as to confine theposition of said flanges and press said flanges against said lateralsides of said roll, and a film passage mouth formed between said shellhalves for passing said photographic film therethrough, a leading end ofsaid photographic film being advanced out of said cassette shell byrotating said spool in an unwinding direction, said method comprisingthe steps of: mating said shell halves together to form said cassetteshell while containing said spool inside shell halves with said flangesmounted to said spool; separating said shell halves to widen said filmpassage mouth to an extent that said confining elements still confinethe position of said flanges; inserting a trailing end of a strip ofsaid photographic film through said widened film passage mouth towardsaid spool; securing said trailing end to said spool; subsequently saidshell halves together again; winding said photographic film into saidcassette shell by rotating said spool in a winding direction.
 38. Amethod as recited in claim 37, further comprising the step of securingsaid shell halves to each other after said winding step.
 39. A method asrecited in claim 38, wherein each of said flanges has curved rim whichis in contact with an outermost convolution of said roll at a limitedlateral portion thereof so as to radially confine the outermostconvolution.
 40. A method as recited in claim 39, wherein saidseparating step comprises the step of pivoting at least one of saidshell halves about a pivot which is located outside said cassette shelland extends parallel to a rotational axis of said spool in a planeincluding said rotational axial and axial joint surfaces of said matedshell halves.
 41. A method as recited in claim 40, wherein saidconfining elements are in contact with said flanges by an amount L whensaid shell halves are separated, and the amount L is not less than 0.3mm under conditions that the external diameter of said flanges is 21.2mm, the radial distance from said pivot to said rotational axis is 14mm, the radial distance from said rational axis to an inner end of saidconfining elements is 8 mm, and the radius of curvature of said rim ofsaid flange is 0.2 mm.
 42. An apparatus of manufacturing a photographicfilm cassette having a cassette shell consisting of a pair of shellhalves, a spool rotatably mounted in said cassette shell, a roll ofphotographic film tightly wound on said spool, a pair of flanges mountedon opposite ends of said spool so as to hold lateral sides of said rolland prevent loosening of said roll, confining elements formed on theinner periphery of said cassette shell so as to confine the position ofsaid flanges and press said flanges against said lateral sides of saidroll, and a film passage mouth formed between said shell halves forpassing said photographic film therethrough, a leading end of saidphotographic film being advanced out of said cassette shell by rotatingsaid spool in an unwinding direction, wherein said spool with saidflanges is mounted in said cassette shell before said photographic filmis wound about said spool, said apparatus comprising: first means forholding said shell halves, containing said spool with said flangestherein, together; second means for separating said shell halves for aperiod of time to widen said film passage mouth to an extent that saidconfining elements still confine the position of said flanges andthereafter mating said shell halves; third means for inserting atrailing end of a trip of said photographic film through said widenedfilm passage mouth toward said spool to secure said trailing end to saidspool; and fourth means for winding said photographic film into saidcassette shell by rotating said spool after said trailing end secured tosaid spool.
 43. An apparatus as recited in claim 42, further comprisingmeans for securing said shell halves to each other after said fourthmeans completely winds said photographic film into said cassette shell.44. An apparatus as recited in claim 43, wherein said first meanscomprises a pair of clamping members for clamping said shell halvesrespectively, and said second means comprises a mechanism for pivotallymoving one of said clamping device relative to the other.